Phtovoltaic module mounting and installation system

ABSTRACT

A photovoltaic system, comprising: a photovoltaic module attached to a photovoltaic rectangular mount frame; a deflector having a first end rotatably coupled to the mount frame so as to pivot the deflector from a nested position under the photovoltaic module in the mount frame to an installation position raising at least a first side of the mount frame; and a mount foot rotatably coupled to a second end of the deflector so as to pivot the mount foot from a nesting position in a mount foot nesting indention in the deflector to an installation position planar to a mounting surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority benefit under 35 USC 120 fromco-pending U.S. patent application Ser. No. 15/231,768, filed on Aug. 8,2016, which application claims priority benefit to U.S. provisionalpatent application Ser. No. 62/352,015 filed on Jun. 19, 2016; Ser. No.62/301,978 filed on Mar. 1, 2016; Ser. No. 62/257,695 filed on Nov. 19,2015; and Ser. No. 62/202,749 filed on Aug. 7, 2015, the subject matterof which are hereby incorporated by reference in their entireties.

FIELD OF THE INVENTION

The present disclosure relates in general to the fields of solarphotovoltaics (PV), and more particularly to solar photovoltaics moduleand mount systems.

BACKGROUND

Requirements for solar photovoltaic (PV) module installations ofteninclude numerous challenging thresholds such as a minimum wind upliftresistance and a minimum snow load weight the installation will support.This has resulted in solar PV systems often requiring labor intensiveand time consuming installation. For example, solar PV roof systemstypically utilize roof penetration or a ballast to secure a solar moduleto the roof mounting structure. Roof penetration solar PV systems, forexample, require roof penetration hardware materials and installationthus increasing system weight and installation time and labor. Andballast solar PV systems, for example, require the placement of heavyweighted objects, often cinder blocks, thus increasing system weight andinstallation time and labor.

BRIEF SUMMARY OF THE INVENTION

Therefore, a need has arisen for a PV system requiring reducedinstallation resources and having minimized mounting surface impact. Inaccordance with the disclosed subject matter, PV systems requiringreduced installation resources and having minimized mounting surfaceimpact are provided which may substantially eliminate or reducesdisadvantages and deficiencies associated with previously developed PVsystems.

According to one aspect of the disclosed subject matter, a photovoltaicsystem is provided. The photovoltaic system comprises a photovoltaicmodule attached to a photovoltaic mount frame, the mount frame having arectangular shape. A deflector is attached to the mount frame by arotatable deflector and mount frame attachment wherein the deflectorpivots around the rotatable deflector and mount frame attachment from anesting position under the photovoltaic module in the mount frame to aninstallation position raising at least a first side of the mount frame.A mount foot is attached to the deflector by a rotatable mount foot anddeflector attachment wherein the mount foot pivots around the rotatablemount foot and deflector attachment from a nesting position in a mountfoot nesting indention in the deflector to an installation positionplanar to a mounting surface.

These and other aspects of the disclosed subject matter, as well asadditional novel features, will be apparent from the descriptionprovided herein. The intent of this summary is not to be a comprehensivedescription of the claimed subject matter, but rather to provide a shortoverview of some of the subject matter's functionality. Other systems,methods, features and advantages here provided will become apparent toone with skill in the art upon examination of the following FIGUREs anddetailed description. It is intended that all such additional systems,methods, features and advantages that are included within thisdescription, be within the scope of any claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The features, natures, and advantages of the disclosed subject mattermay become more apparent from the detailed description set forth belowwhen taken in conjunction with the drawings (dimensions, relative orotherwise not drawn to scale) in which like reference numerals indicatelike features and wherein:

FIG. 1 is a front perspective view of a PV system in accordance with thedisclosed subject matter;

FIG. 2 is a rear perspective view of a PV system in accordance with thedisclosed subject matter;

FIGS. 3 and 4 are rear and front perspective views, respectively, of a2×2 array of installed PV systems of four PV systems;

FIG. 5 is a top view of a 2×2 array of installed PV systems of four PVsystems;

FIG. 6 is a side view of PV systems of FIG. 5;

FIG. 7 is a rear perspective view of a PV system;

FIGS. 8A, 8B, and 8C are side views of an attached deflector and mountfoot;

FIGS. 9A, 9B, and 9C are views showing a rotatable hook and roddeflector and mount foot attachment;

FIGS. 10A, 10B, and 10C are side views of an attached deflector andmount frame;

FIG. 11 is omitted;

FIG. 12 is a front perspective view of a PV system;

FIG. 13 is a front perspective of a stack of PV systems;

FIGS. 14A, 14B, 14C, and 14D are views showing a rotatable hook and rodmount frame and deflector attachment;

FIGS. 15A and 15B show the structures of FIGS. 14B and 14D,respectively, with an additional guiding rib;

FIGS. 16A, 16B, and 16C are side perspective views of steps in theinstallation of a 2×2 array of PV systems in accordance with thedisclosed subject matter;

FIG. 17 is a top view of a mount frame without an attached PV module;

FIG. 18 is a bottom view of a mount frame;

FIG. 19 is a bottom view of the mount frame of FIG. 18 and showing anested deflector;

FIG. 20 is a perspective view of an alternative PV system installation;

FIG. 21 is side view of the PV systems of FIG. 20;

FIG. 22 is a front perspective view a column of PV systems; and,

FIGS. 23A and 23B are front perspective views of two PV systems in arow.

DETAILED DESCRIPTION

The following description is not to be taken in a limiting sense, but ismade for the purpose of describing the general principles of the presentdisclosure. The scope of the present disclosure should be determinedwith reference to the claims. Exemplary embodiments of the presentdisclosure are illustrated in the drawings, like aspects and identifiersbeing used to refer to like and corresponding parts of the variousdrawings.

And although the present disclosure is described with reference tospecific embodiments, fabrication and installation processes, andmaterials, one skilled in the art could apply the principles discussedherein to other solar modules and mount structures, fabrication andinstallation processes, as well as alternative technical areas and/orembodiments without undue experimentation.

The comprehensive solution for PV module mounting and installationprovided advantageously allows for reduced solar system weight, reducedinstallation time and complexity, increased packing density forshipping, self-aligning and interlocking PV system array installation,increased installed PV system array density, and minimized mountingsurface impact through the elimination of mount surface penetration andweight for ballast while exceeding wind uplift resistance and snow loadrequirements. Many of these advantageous are particularly applicable tohorizontal plane commercial rooftops, including those rooftops havingstrict weight restrictions, for flat roof solar array installation.

The PV module mount system provided is particularly designed for the useof lightweight materials, such as outdoor grade plastics andfiber-reinforced composite materials such as fiber reinforced plastics.Particularly advantageous PV module mount system materials includematerials such as polymerics, polyolefins, and reinforced polymeric orpolyolefin materials (e.g., reinforced by materials such as glass orcarbon fibers), to enhance PV system weight reduction. Additionally,non-metal materials may eliminate or reduce PV mount groundingrequirements. Materials such as polymeric materials, including compositeglass or carbon filled polymeric materials and particularly includingcomposite glass or carbon filled polyimide materials and composite glassor carbon filled polybutylene terephthalate (PBT) materials, areparticularly advantageous for use as the mount frame, deflector, mountfeet, and all other mount system structural aspects outside of the PVmodule. Additionally, to reduce fabrication costs, in consideration withother factors, the PV mount system may be formed by an injectionmolding, structural foam molding, compression molding, thermoforming, orthree-dimensional printing fabrication process using these lightweightmaterials. Additional key fabrication advantages may include asymmetrical design for mirror parts fabrication of parts of a mountsystem structural aspect followed by attachment of the mirrored parts tocomplete the structural aspect.

A PV module, for example comprising electrically connected encapsulant(e.g., EVA) embedded solar cells, a cover material such as glass orplastic, and module back sheet as well as corresponding PV modulewiring/cabling may be readily integrated with the disclosed PV modulemount system before shipping to an installation location—thus, forming acomprehensive and integrated PV module and mount system with highdensity packing characteristics and improved ease of installation whilereducing required installation resources such as labor and tools. PVsystem weight reduction may be further enhanced through lightweight PVmodule materials such as thin cover glass (e.g., cover glass having athickness less than 2.5 mm).

FIG. 1 is a front perspective view of a PV system in accordance with thedisclosed subject matter. Solar PV module 2 is attached to mount frame 4having front attachments 8 shown as two pairs of two upwardly openfacing hooks. Deflector 6 is attached to and raises the back of mountframe 4. The deflector supports the back of the mount frame to providethe desired PV system tilt. The PV module attached to the mount framemay have known PV module sizes and orientations, for example a 6×10 celllandscape orientation PV module.

FIG. 2 is a rear perspective view of a PV system in accordance with thedisclosed subject matter. Two back mount feet 10, each having twofrontside hooking rods 12 and two backside hooking rods 14, are attachedto deflector 6 by deflector bottom hooks 16 and frontside hooking rods12. Two deflector mount feet nests 18, each including four mount feethooking rod nests 20, are indentions in deflector 6 for the nesting ofback mount feet 10. Side connector 22 is attached to deflector 6 atpivot attachment 24 in deflector side connector nests 26 having sideconnector grasp indentions 28. Deflector side connector nests 24 areindentions in deflector 6 for the nesting of side connector 22 and sideconnector grasp indentions 26 allow for the grasping and side connector22. Mount frame 4 is flared from top to bottom such that the rectangularperimeter of the top of mount frame 4 is less than the rectangularperimeter of the bottom of mount frame 4. An advantage of a flared (ortapered from bottom to top) mount frame, particularly a flared mountframe on the same mount frame side as the deflector, is the flared mountframe may be used to align the deflector at an angle less than ninetydegrees to the mounting surface (e.g., a roofing surface), in otherwords a sloped angle, to improve wind flow and wind uplift resistance.In an alternative embodiment, only the mount frame on the same mountframe side as the deflector is flared and the other sides are not (e.g.,for example the other sides may be perpendicular). A sloped angledeflector may also improve PV system load bearing. Additionally, theinternal surface of the mount frame on the deflector side may be used tocreate a strong locking and bracing mechanism for the deflectorsallowing the deflector, and therefore the entire structure, to carrymuch higher vertical loads than a deflector mounted on the outside ofthe frame.

Mount feet nests in the deflector, for example, may be indentions in thethickness of the deflector to nest the mount feet structure or may be aconformal deflector design having a uniform deflector thickness suchthat the uniform deflector thickness is designed to nest the mount feetstructure.

FIGS. 3 and 4 are rear and front perspective views, respectively, of a2×2 array of installed PV systems of four PV systems of FIGS. 1 and 2.PV system M1 is attached to PV system M2; PV system M3 is attached to PVsystem M4 and using side connectors 36 (e.g., side connector 22 shown inFIG. 2). Side connectors 36 provide alignment of the side by side PVsystems and interlock the side by side PV systems together. Spacingbetween side by side PV systems may be extremely small, for example inthe range of millimeters, for high density PV system array installation.Feet 30, 32, and 36 are adhered (e.g., using double sided adhesive tapeor glue) to a mounting surface. Feet 30 are attached to PV systems M1and M2 (e.g., by a front mount frame attachment) to secure PV systems M1and M2 to the mounting surface. Feet 32 are attached to PV systems M1and M2 (e.g., by a rotatable back deflector connection) and are attachedto PV systems M3 and M4 (e.g., by a front mount frame attachment) tosecure PV systems M1 through M4 to the mounting surface and interlock PVsystems M1 to M3 and M2 to M4. Feet 34 are attached to PV systems M3 andM4 (e.g., by a rotatable back deflector connection) to secure PV systemsM3 and M4 to the mounting surface. Feet 30, 32, and 34 in combinationwith a front mount frame attachment provide alignment for the array andparticularly the alignment of a column of PV systems (i.e., PV systemsattached front to back), for example the array column made of PV systemsM1 and M3. A row of PV systems, for example, is made of PV systems M1and M2. Thus, the columns of the PV array of FIG. 3 are 4 areself-aligning according to the design of the foot to front mount frameattachment. This self-alignment may be enhance by guiding ribs on thefoot, for example guiding ribs aligning front mount attachment hooksinto a rod attachment structure on the foot. Alternative attachmentstructures may include a pivot attachments and insertion sleeveattachments.

FIG. 5 is a top view of a 2×2 array of installed PV systems of four PVsystems. Deflector 38 raises PV systems M1 through M2. Details in thedeflector, such as those shown in deflector 6 of FIGS. 1 through 4, havebeen omitted for drawing clarity. FIG. 6 is a side view of PV systems M1and M3 in FIG. 5. Adhesive 40 on the bottom of feet 30, 32, and 34adheres the mount feet to a mounting surface.

FIG. 7 is a rear perspective view of the PV system of FIG. 2 with cableguard 42 attached to the mount frame and cable hole 44 in the mountframe for PV module wire management. Wires and cabling associated withthe PV module attached to the mount frame may be routed through cablehole 44 and transferred along cable guard 42 for electrical connectionto adjacent PV systems. Cable hole 44 provides an access hole for PVmodule wires/cables and cable guard 42 provides wire guidance to anadjacent PV system for electrical connection. The integrated PV moduleand PV module mount system of the present disclosure may be shipped withPV module wires/cables stored below the PV module in the mount frame andduring installation (e.g., before securing the PV system to the mountingsurface) the module wires/cables may be pulled through the access holeand the cable guard (e.g., with external wire connections positioned oneither end of the cable guard for connection to adjacent PV systems),thus providing improved PV module wire management and PV systeminstallation ease such that after attaching a PV system to a mountingsurface adjacent PV systems may be readily electrically connected.Alternatively, the PV system may be shipped with the module wires/cablesbe pulled through the access hole and the cable guard such that thecable guard provides wire/cable protection during shipping.

FIGS. 8A through 8C are side views of an attached deflector and mountfoot showing mount foot 60 pivoting around rotatable attachment 62 ofdeflector 56 to mount foot 60. Deflector 56 is attached to mount frame52 and is aligned respective to the mount surface at the same angle asthe flared sidewall 64 of mount frame 52 for installation (referred toas deflector installation position). Note that although shown with aledge between flared sidewall 64 and deflector 56, the deflector, andmount frame, and deflector and mount frame attachment may be structuredand designed to minimize this ledge such that exterior surfaces offlared sidewall 64 and deflector 56 are substantially planar forimproved wind uplift resistance. Mount frame has front attachment hooks54 (e.g., for attachment to a mount foot). FIG. 8A shows mount foot 60in installation position, in other words planar to a mounting surface,for adhesion to a mounting surface. FIG. 8B shows mount foot 60 inpartial rotation pivoting around rotatable attachment 62 for nestinginto deflector 56. FIG. 8C shows mount foot 60 in PV system shippingposition with mount foot 60 completely nested into deflector 56 (i.e.,mount foot 60 nested into a deflector nest in deflector 56)—note mountfoot 60 is not visible in nested position from the side view of FIG. 8C.

FIGS. 9A through 9C are views showing a rotatable hook and rod deflectorand mount foot attachment. Deflector 70 has mount foot nest 74,including mount rod nest 76, conforming to the shape of mount foot 78and mount foot attachment rods 80. Deflector bottom hooks 72 arepositioned at the bottom of the deflector for attachment to mount footattachment rods 80. FIG. 9A shows deflector 70 and mount foot 78unattached. The attachment of deflector bottom hooks 72 and mount footattachment rods 80 forms rotatable deflector and mount attachment 82.FIG. 9B shows deflector 70 and mount foot 78 attached as rotatabledeflector and mount attachment 82 with mount foot 78 in installationposition. Mount foot 78 may pivot around rotatable deflector and mountattachment 82 back and forth from installation position to a nestedposition such that mount foot 78 and mount foot attachment rods 80 nestin mount foot nest 74 and mount rod nest 76 and the bottom of mount foot78 forms a planar surface with deflector 70. FIG. 9C shows deflector 70and mount foot 78 attached as rotatable deflector and mount attachment82 with mount foot 78 in nesting position with a planar surface formedof the bottom of mount foot 78 and deflector 70. In other words, mountfoot 78 pivots around rotatable deflector and mount attachment 82 frominstallation position (installation position shown in FIG. 9B) tonesting position (nesting position shown in FIG. 9C) and vice versa.

FIGS. 10A through 10C are side views of an attached deflector and mountframe showing deflector 56 pivoting around a rotatable attachment insidemount frame 54. The structure of FIGS. 10A through 10C is consistentwith the structure of FIGS. 8A through 8C. Deflector 56 is attached tomount frame 52 and is aligned respective to the mount surface at thesame angle as the flared sidewall 64 of mount frame 52 for installation(referred to as deflector installation position). Mount frame has frontattachment hooks 54 (e.g., for attachment to a mount foot). FIG. 10Ashows deflector 56 in installation position consistent with FIG. 8C.FIG. 10B shows deflector 56 in partial rotation pivoting around arotatable attachment inside mount frame 54 for nesting into mount frame54. FIG. 10C shows deflector 56 PV system in shipping position withdeflector 56 completely nested in mount frame 54 (i.e., deflector 56nested under a PV module, and under corresponding PV module attachmentsurfaces such as an internal ledge and ribs, inside mount frame 54)—notedeflector 56 is not visible in nested position from the side view ofFIG. 10C.

FIG. 12 is a front perspective view of PV system, for example having astructure consistent with the PV system of FIGS. 1 and 2, in shippingposition with a deflector in nested position under PV module 80 which isattached to mount frame 82. Note the lip of the sidewalls of mount frame82 exposed above PV module 80. Exposed mount frame sidewall lip may beadvantageous for protecting PV module 80 when stacking the PV systems ofFIG. 12 (e.g., the exposed lip of an underneath PV system in a stack ofPV systems provides a set-off from the stacked PV system above such thatthere is nothing touching the PV module of the underneath PV system).Alternatively, the mount frame may be designed such that the PV modulemay be attached flush with the sidewalls of the mount frame resulting inan unexposed sidewall lip. FIG. 13 is a front perspective of a stack ofthe PV system of FIG. 12. In shipping position, with a rear deflectornested inside the frame, the PV system disclosed herein providesextremely high PV system shipping density.

FIGS. 14A through 14D are views showing a rotatable hook and rod mountframe and deflector attachment. FIG. 14A is a rear perspective view ofdeflector 90 having deflector top hooks 98 and deflector bottom hooks100. Mount foot nest 92 includes top mount foot attachment nest 96 andbottom mount foot attachment nest 94 (e.g., conformal mount footattachment nests for an alternative design of the mount foot attachmentrod of FIG. 9). Side connection indention 102 and side connector graspindentions 104 are primarily shown here for orientation context of thedeflector throughout FIGS. 14A through 14D. FIG. 14B shows a bottom upperspective of a mount frame having flared side wall 106 and internalledge 108. Mount frame attachment rods 110 are supported by attachmentrod support ribs 112 connected to the internal surface of flared sidewall 106 and the bottom surface of internal ledge 108. In other words,the PV module is attached to the opposite side of internal ledge 108 andmount frame attachment rods 110 and attachment rod support ribs 112 arepositioned under the PV module and separate from the PV module byinternal ledge 108.

FIG. 14C shows the deflector of FIG. 14A attached to the mount frame ofFIG. 14C at rotatable deflector and mount frame attachment 114.Rotatable deflector and mount frame attachment 114 is formed of attachedmount frame attachment rods 110 and deflector top hooks 98 thus forminga pivot around which deflector 90 rotates back and forth between anesting position (deflector nesting position shown in FIG. 14C) and aninstallation position (deflector installation position shown in FIG.14D). In other words deflector 90 pivots around rotatable deflector andmount frame attachment 114. FIG. 14C shows deflector 90 in nestingposition and positioned against internal ledge 108. FIG. 14D showsdeflector 90 in installation position and positioned against flared sidewall 106. In installation position, as deflector 70 is positionedagainst flared side wall 106, deflector 70 aligns with the angle of theflare of flared side wall 106.

Well positioned snapping or locking attachments may help hold or lockthe deflector and mounting feet in nesting position. For theinstallation position, the mount feet align with the mounting surface.

FIGS. 15A and 15B show the structures of FIGS. 14B and 14D,respectively, with additional guiding rib 116 to help deflector 70 snapor lock into nesting and installation positions. Guiding ribs such asguiding rib 116 may be particularly advantageous to snap or lock thedeflector into installation position or otherwise signify the deflectoris in installation position.

FIGS. 16A through 16C are side perspective views of steps in theinstallation of a 2×2 array of PV systems in accordance with thedisclosed subject matter. FIG. 16A shows PV system S1 with deflector ininstallation position and rear mounting feet 117 nested in thedeflectors of S1 and S2. Front attachment hooks 116, for exampleattachment hooks such as those shown in FIG. 1, are attached to thefront of the mount frames of PV systems S1 and S2. PV system S2 is beingset down next to PV system S1. In some instances, a temporary spacersuch as a piece of wood (e.g., a 2″ by 4″ piece of lumber) may be usedto position adjacent systems side by side next to each other in rows.FIG. 16B shows the first row of the array formed of PV systems S1 andS2. Rear mounting feet 117 have been rotated out of nesting position toinstallation position and adhered to a mounting surface. Front mountingfeet 118, for example having the rod structure of the mount footattachment rods on the mount foot shown in FIGS. 9A through 9C, havebeen hooked and swung onto front attachment hooks 116 of PV systems S1and S2 (i.e., front mounting feet 118 hooked onto front attachment hooks116 and then front mounting feet 118 swung into installation positionfor adhesion to the mounting surface) and then adhered to the mountingsurface. Side connector 119 attaches and interlocks the deflector of PVsystem S1 to PV system S2. Side connector 119 may be used to align thespacing between side by side PV systems forming rows before the PVsystems are secured to the mounting surface via adhered mount feet. FIG.16C shows the second row of the array being installed. PV systems S3 andS4 form the second row of the array and are structurally consistent withPV systems S1 and S2. PV systems S3 and S4 are shown with rear mountingfeet nested in the deflectors of PV systems S3 and S4. PV system S3 isshown after the front attachment hooks of PV system S3 have been hookedand swung onto the rear mounting feet of PV system S1 (i.e., frontattachment hooks of PV system S3 hooked onto mount foot attachment rodsof the already mounting surface adhered rear mounting feet of PV systemS1 and then PV system S3 swung into installation position for adhesionto the mounting surface). FIG. 16C shows the front attachment hooks ofPV system S4 being hooked into the mount foot attachment rods of thealready mounting surface adhered rear mounting feet of PV system S2.Thus, the attachment of the front attachment hooks (shown as a hook andswing attachment, the arrow of FIG. 16C indicating the direction of thehook as the PV system is lowered into an installation position) to amounting surface adhered mount foot provides self-alignment andinterlocking of the column of PV systems (e.g., the column of PV systemsS2 and S4 or the column of PV systems S1 and S3).

A detailed installation process may include the following steps: Snaptwo parallel chalk lines 49 inches apart at leading edge of front row ofmodules (or alternatively snap one chalk line, for example a linesnapped in alignment with the lower edge of the deflector); Apply firstPV system on one end of first row—front edge aligning with first chalkline; Lay first PV system back into installation position, back (rear)deflector swings out for support; Lay second PV system to side of firstmodule, 1.5″ gap between PV systems, front edge aligning with firstchalk line; Lay second PV system into installation position, backdeflector swings out for support; Lay all subsequent PV systems in thefirst row side by side with 1.5″ gap between PV systems; Lay all firstrow PV systems into installation position, back deflector swings out forsupport; With all first row PV systems placed into position, preparewith cleaner/primer the roof surface adjacent to each rear foot retainedin nesting position in the deflector (e.g., two per PV system); Allowcleaner/primer to dry/cure; Pull release liner off each foot, swing eachfoot down to apply adhesive to cleaned roof area, set each rear footdown to alignment with rear chalk line (#2); After completion of allrear feet attachment to roof, apply cleaner/primer adjacent to frontfeet mount area for first row; Allow cleaner/primer to dry/cure; Setfront feet onto front hooks (two per module) for each front row module;Pull release liner off each foot, swing each foot down to apply adhesiveto cleaned roof area, set each front foot down to alignment with frontchalk line (#1); Engage each East/West mechanical connection (i.e., aside by side connector, such as side connector 119 in FIG. 16B, in anEast/West aligned array) from module to module in first course.Importantly, it is advantageous to establish the cable connection andthe engagement of the East/West mechanical connection before the feetare adhered to the surface; Connect male-to-female electrical connectorsin adjacent PV systems in first row; With first row fully installed,place home run cable in cable tray on top edge of PV systems runningfrom PV system to consecutive PV system left to right or right to left;Place first PV system of second row in position behind first PV systemof second row; Engage (hook and swing) front hooks of first PV system ofsecond row into receptacles on rear foot of first PV system in firstrow; Lay first PV system of second row of PV systems into installationposition, back deflector swings out for support; Engage (hook and swing)front hooks of second PV system of second row into receptacles on rearfoot of second PV system in first row; Lay second module of secondcourse of modules into installation position, back deflector swings outfor support; Engage (hook and swing) front hooks of all subsequent PVsystems in the second row into receptacles on rear foot of eachcorresponding PV system of the first row. Lay each subsequent moduleinto position; With all of second row PV systems placed into positionclean/primer each roof area adjacent to the rear foot of the second row;Allow cleaner/primer to dry/cure; Pull release liner off each rear footof second row, swing each foot down to apply adhesive to cleaned roofarea, set each rear foot down; Engage each East/West mechanicalconnection (i.e., a side by side connector, such as side connector 119in FIG. 16B, in an East/West aligned array) from PV system to PV systemin second row; Connect male-to-female electrical connectors in adjacentPV systems in second row; With second row fully installed, place homerun cable in cable tray on top edge of PV systems running from PV systemto consecutive PV system left to right or right to left; Repeatplacement of third row and subsequent rows of PV systems as noted above.

FIG. 17 is a top view of a mount frame without an attached PV module.Sidewall 120 is flared from top to bottom (i.e., having a smallerrectangular perimeter at the top frame opening as compared to theperimeter of the bottom frame opening). Internal ledge 122 is attachedto and runs around the internal perimeter of sidewall 120. Supportstructures under internal ledge 122 may provide structure support andstiffening to internal ledge 122—for example guiding rib 116 of FIGS.15A and 15B may also provide support and stiffening to internal ledge108. Support ribs 126 and internal ledge 122 may be used as a surfacefor module attachment as well as for mount stiffening and structuralsupport. Handle 128 provides a handle to carry the PV system (with andwithout an attached PV module) from the backside. Front attachment hooks124 are positioned on sidewall 120 at the front of the mount frame.

FIG. 18 is a bottom view of the mount frame of FIG. 17. Mount frame anddeflector attachment 130 (e.g., a rotatable attachment design similar tomount frame attachment rods 110 and attachment rod support ribs 112 ofFIG. 14B) provides a mount frame to deflector attachment.

FIG. 19 is a bottom view of the mount frame of FIG. 18 and showing adeflector nested in the mount frame. Top deflector attachments 138 ofdeflector 132 (e.g., a rotatable attachment design similar to deflectortop hooks 98 of FIG. 14A) are attached to deflector attachment 130—thusforming a rotatable attachment about which deflector 132 may pivot. Feet134 are attached to deflector 132 via mount foot and deflectorattachment 136 (e.g., a rotatable attachment design similar to rotatabledeflector and mount attachment 82 of FIGS. 9B and 9C). Feet 134 areshown in nesting position nested in deflector 132.

FIG. 20 is a perspective view of an alternative PV system installationdesign in accordance with the disclosed subject matter. This design maybe referred to as an east west PV system array as compared to the arrayshown in FIGS. 3 through 6 and 16A through 16C which is referred to as anorth south PV system array. The array of FIG. 20 is formed of four rowsof PV systems (row 1=P1-P2, row 2=P3-P4, row 3=P5-P6, row 4=P7-P8) andtwo columns of PV systems (column 1=P1-P3-P5-P7, column 2=P2-P4-P6-P8).Front feet 140 are attached to the front attachments on the front sidesof the PV systems of row 2 and row 3. Rear (back) feet 142 are attachedto deflectors on the rear (back) sides PV systems of row 3 and row 4.And front feet 144 are attached to the front attachments on the frontsides of the PV systems of row 4. Note in this design there are fourfront mounts and four rear mounts corresponding to each PV system.

FIG. 21 is side view of the PV systems of FIG. 20, specifically FIG. 21is a side view of the PV systems P6 and P8. Adhesion layer 146 is on thebottom of feet 140, 142, and 144 to adhere the feet to a mountingsurface.

FIG. 22 is a front perspective view a column of PV systems in a northsouth PV system array with a side deflector. Side deflector 150 may beattached to PV systems at the end of a row to further improve windresistance.

FIGS. 23A and 23B are front perspective views of two PV systems in a row(side by side) and showing an alternative side by side (east-west)connector design. Swing attachment 164 on mount frame 160 of a first PVsystem for self-alignment and interlocking with swing attachment snap166 on mount frame 162 of a second PV system. FIG. 23A shows swingattachment 164 unattached to swing attachment snap 166 and FIG. 23Bshows swing attachment 164 attached to swing attachment snap 166.

High strength and water tight attachment and adhesion to known roofingmaterials (e.g., with reference to flat commercial roofs, thermoplasticroof membranes such as polyvinyl chloride PVC, PVC alloys or compoundedthermoplastics, thermoplastic olefin TPO, chlorinated polyethylene CPE,or asphalt/bitumen) are key characteristics of the foot to mountingsurface adhesion. Advantageously, foot to mounting surface adhesion maybe performed by a double sided adhesive tape such that the tape isattached to the foot before shipping the PV system. Butyl adhesive tapesparticularly may provide high strength and water tight attachment offoot to mounting surface. Preparation of the mounting surface prior toapplication of the foot attached adhesive tape may improve adhesion.Alternative foot to mounting surface adhesion systems include aninductively heated thermoplastic that may be combined with adhesivelayers or an injected two part reactive adhesive injection through thefoot to the mounting surface. In yet another embodiment, a multi-partadhesion system may be used to first bond a plate to the bottom of thefoot based on the foot material and then adhere the plate to themounting surface (e.g., roofing material) based on the mounting surface(e.g., roof material).

In addition to the lightweight materials for the PV module mount systemoutlined above, for example outdoor grade plastics and fiber-reinforcedcomposite materials, the following materials and materialcharacteristics are provided. Fiber-reinforced composite material may beused for the integrated module support and mounting sub-structure may bemade using glass fibers, aramid fibers, carbon fibers, or a combinationthereof. Lower cost options such as glass fibers forglass-fiber-reinforced plastics (glass FRP) may be advantageous. Thecomposite material (FRP) sub-structure should have sufficient thicknessand/or strengthening elements (such as ribs and/or lips, etc.) tofurther enhance mechanical strength and to reduce warpage/bow uponmechanical load while meeting the lightweight requirements (in someinstances with the total weight of the module and its integrated supportand mounting sub-structure being less than approximately 2 lb/ft.sup.2or less than approximately 10 kg/m.sup.2). The fiber-reinforcedcomposite support and mounting material sub-structure (e.g., the PVmount system) may either directly serve as the PV module laminatedback-sheet or attach to the module back-sheet.

As noted above, weight characteristics of the PV system may be furtherenhanced with PV module materials. The following materials and materialcharacteristics are provided. Solar photovoltaic module laminatecomprising a lighter weight thin frontside cover glass (e.g., withtempered cover glass thickness of less than or equal to 2.5 mm, and evenmore advantageously a glass thickness in the range of approximately 0.05mm to approximately 2 mm, depending on the application and maximumweight allowance) and a composite material (such as a suitablefiber-reinforced plastic: FRP) mounting and support structure oppositethe cover glass side, with a plurality of crystalline silicon solarcells, electrically connected in series or a combination of hybridseries-parallel, sandwiched and laminated between the cover glass andthe composite plastic support structure.

The PV system provides for substantially reduced installation time foran array of solar panels and this technical disclosure in part providesa lightweight (e.g., through materials and reduced material use)photovoltaic solar module mount. Technical features include, forexample, an integrated foldable high packing density module mount withfoldable and nestable deflectors and foldable and nestable adhesivemounting feet for fast module mount installation and surface attachmentwithout surface (e.g., roof) puncture or ballasting. Additionally,technical features include, for example, PV system to PV systemmechanical interlocking (north south interlocking and east westinterlocking) providing PV system self-alignment and PV system to PVsystem electrical connection (e.g., side by side connection) andwire/cable management.

The PV module is supported and adhered within the rack mount frame. Therack mount frame may comprise a rectangular outer housing with ribs or acontinuous sheet for supporting the solar panel within the outerhousing. The rack mount frame has a peripheral attachment (e.g., hooks)on the rack mount frame side closest to the ground for attaching to afeet having an attachment (e.g., mounting feet rod structure) on theforward adjacent PV system mounting feet—for example, this attachmentmay be used for the front to back attachment in a “north-south” PV arrayto mounting system attachment.

The nestable and movable deflectors may be attached to mount rack framefor example by a rotating hinge or a hook and rod system for rotationfrom a shipping/nested position such that the deflector snaps into placewithin the mount rack frame (such that the deflector is parallel to therack mount frame) and the deflector may be rotated outwards from themount frame into an installation position (such that deflector is in therange of perpendicular to the rack mount frame) for supporting one sideof the rack mount frame off the ground to angle the PV module supportedin the rack mount frame off the ground (for example one side of thepanel angled in the range of 3 to 30.degree. off the ground and moretypically in the range of 10 to 20.degree. as compared to the horizontalplane of the surface, for example a roof). When the deflector is nestedthe rack mount frame with an adhered PV module, the PV system may bestacked with other PV systems having adhered PV modules for high densityshipping.

The mounting feet (e.g., comprising mounting feet rod structure for ontwo sides, on one side for attachment to the deflector of acorresponding PV system and on the other side for attachment to anadjacent PV system via the adjacent PV system's peripheral hooks orother attachment mechanism) are attached to the nestable and movabledeflectors for example by a rotating hinge or a hook and rod system forrotation from a shipping/nested position such that the mounting feetsnap into place within the deflector frame (for example in indentions inthe deflector accommodating the mounting feet rod structure, themounting feet rod structure for attaching to a hook attached to a rackmount frame in an adjacent PV system) and the mounting feet may berotated from the mount frame into an installation position for adhesionto the ground or a surface.

Thus in a shipped position the mounting feet nest and snap into thedeflector and the deflector nests and snaps into the rack mount frame.In an installation position the deflector may be rotated outwards fromthe rack mount frame into a snapped installation position to support oneside of the rack mount frame and the feet are rotated outwards from thedeflector to adhere the PV system to the ground or a surface. The PVsystem is now installed (adhered and secured). The next PV system (e.g.,via hooks on its peripheral rack mount) may then be attached to theexposed rod structure of the just adhered mounting feet. Thus securingthe lower side of this next PV system to the installed PV system (and a“north-south” PV system to PV system attachment) and the process mayrepeat itself as the deflector on the next PV system may be rotated intoan installation position and so forth.

Pertaining to side by side interlocking attachment, or also called“east-west” attachment, a nestable east west (side) connector may beattached to the deflector or the mount frame. For example, the east westconnector may be nested into the deflector during shipping (similar tothe mounting feet), and rotated outwards for connection to an adjacentside by side (“east-west”) PV system during installation for securingthe array of PV systems in the east-west direction. Thus, forming asecured array of PV systems attached to the ground via the mountingfeet, attached to one another from front to back (“north-south”) via theperipheral hooks on the low end of the mount rack frame and the rodstructure on the mounting feet, and attached to one another side by side(“east-west”) via the east west connector which secures the PV system toan adjacent (east west adjacent) PV system.

The foregoing description of the exemplary embodiments is provided toenable any person skilled in the art to make or use the claimed subjectmatter. Various modifications to these embodiments will be readilyapparent to those skilled in the art, and the generic principles definedherein may be applied to other embodiments without the use of theinnovative faculty. Thus, the claimed subject matter is not intended tobe limited to the embodiments shown herein but is to be accorded thewidest scope consistent with the principles and novel features disclosedherein.

What is claimed is:
 1. A photovoltaic system, comprising: a photovoltaicmodule attached to a photovoltaic rectangular mount frame; a deflectorattached to said mount frame by a rotatable deflector and mount frameattachment, wherein said deflector is configured to pivot around saidrotatable deflector and mount frame attachment from a first positionunder said photovoltaic module in said mount frame to an installationposition raising at least a first side of said mount frame; and a mountfoot attached to said deflector by a rotatable mount foot and deflectorattachment, wherein said mount foot is configured to pivot around saidrotatable mount foot and deflector attachment from a nesting position ina mount foot nesting indention in said deflector to an installationposition planar to a mounting surface.
 2. The photovoltaic system ofclaim 1, wherein said photovoltaic module comprises a plurality ofelectrically connected encapsulant embedded solar cells.
 3. Thephotovoltaic system of claim 2, wherein said photovoltaic moduleincludes a glass or plastic cover material and module back sheet.
 4. Thephotovoltaic system of claim 1, wherein said mount frame, saiddeflector, and said mount foot are made of plastic composite.
 5. Thephotovoltaic system of claim 1, wherein said mount frame furthercomprises an internal ledge for photovoltaic module support.
 6. Thephotovoltaic system of claim 1, wherein said mount frame furthercomprises a plurality of internal ribs for photovoltaic module support.7. The photovoltaic system of claim 1, wherein said mount frame, saiddeflector, and said mount foot are made of fiber reinforced plastic. 8.The photovoltaic system of claim 1, wherein said first position of saiddeflector is a nested position within and parallel to the mount frame.9. The photovoltaic system of claim 1, wherein said mount frame includesan attachment hook on a first side of said mount frame; and wherein saiddeflector is attached to a second side of said mount frame opposite saidmount frame first side.
 10. The photovoltaic system of claim 9, whereinsaid second side of said mount frame includes a flared mount frame sidewall.
 11. A stack of photovoltaic systems, comprising: a stack ofphotovoltaic systems formed of at least a first photovoltaic system on asecond photovoltaic system; said first photovoltaic system and saidsecond photovoltaic system each having a photovoltaic module attached toa corresponding photovoltaic mount frame and a deflector, said deflectorhaving at a first end a pivotable mount foot member coupled thereto,said pivotable mount foot member positioned in a nesting position in amount foot nesting indention in said deflector when stacked, whereineach said mount frame has a rectangular shape, each said photovoltaicmodule of said photovoltaic system attached to said mount frame, a lipof said mount frame exposed above said attached photovoltaic module, andsaid deflector attached at a second end to said mount frame by arotatable deflector and mount frame attachment wherein said deflectorpivots around said rotatable deflector and mount frame attachment from anesting position under said photovoltaic module in said mount frame toan installation position raising at least a first side of said mountframe, and wherein said deflector is positioned in the nesting positionwhen stacked.
 12. The stack of photovoltaic systems of claim 11, whereinsaid photovoltaic mount system is made of fiber reinforced plastic. 13.A photovoltaic system, comprising: a photovoltaic module attached to aphotovoltaic rectangular mount frame; a deflector having a first endrotatably coupled to said mount frame so as to pivot the deflector froma nested position under said photovoltaic module in said mount frame toan installation position raising at least a first side of said mountframe; and a mount foot rotatably coupled to a second end of saiddeflector so as to pivot said mount foot from a nesting position in amount foot nesting indention in said deflector to an installationposition planar to a mounting surface.
 14. The photovoltaic system ofclaim 13, wherein the first end of the deflector extends along amajority of at least one side of the rectangular mount frame.
 15. Thephotovoltaic system of claim 13, wherein the deflector includes graspindentions for receiving a side connector attachable to said deflectorfor connecting to another photovoltaic system.
 16. The photovoltaicsystem of claim 13, wherein said mount frame includes an attachment hookon a side of said mount frame and distal to said deflector.
 17. Thephotovoltaic system of claim 13, wherein said photovoltaic modulecomprises a plurality of electrically connected encapsulant embeddedsolar cells.